International Journal of Mechanical and Production

Engineering Research and Development (IJMPERD)

ISSN (P): 2249-6890; ISSN (E): 2249-8001
Vol. 8, Issue 2, Apr 2018, 865-872
© TJPRC Pvt. Ltd

HYBRID OPTIMIZATION OF WEDM PARAMETERS TO PREDICT THE

INFLUENCE ON SURFACE ROUGHNESS AND CUTTING SPEED

FOR NI-BASED INCONEL 600 WROUGHT SUPERALLOY

SANDEEP KUMAR & SUBRAMANI. P

Department of Mechanical Engineering, M. Kumarasamy College of Engg., Karur, Tamil Nadu, India
ABSTRACT

Non-conventional machining processes are the requirements of the fastest growing industries because of the
precision, complex, intricate shape of the work material, higher tolerances and economically. WEDM is a variation and
development of EDM and a spark erosion process in which the material revival takes place due to erosion caused by
electrical sparks. This process is utilized for machining of conductive and difficult-to- machine material irrespective of
hardness with the help of thin wire electrode. This research aims to examine the influence of Wire Electro-discharge
Machining (WEDM) parameters on surface roughness (SR) and cutting speed to improve the productivity with a high
surface finish of Ni-based super alloy namely Inconel 600 wrought super alloy. In this experimental work, the hybrid

Original Article
optimization has been done for the machining of Ni-based wrought Inconel-600 super alloy using standard brass wire.
The peak current (IP), taper angle, pulse on Time (Ton), a pulse of time (Toff) and die-electric fluid pressure had selected
as operation constraints to conduct experimental trials. The cutting rate and surface roughness (SR) were considered as
output responses. The experimental outcomes were optimized by Gray relational analysis coupled with a Taguchi hybrid
optimization method. The optimized parameters by multi-parametric optimization method showed the considerable
improvement in the process and will facilitate the WEDM industries to improve the productivity with a higher surface
finish.

KEYWORDS: WEDM, Ni-based Superalloy, Surface Roughness, Cutting Rate & Multi-Parametric Hybrid Optimization

Received: Feb 20, 2018; Accepted: Mar 04, 2018; Published: Mar 15, 2018; Paper Id.: IJMPERDAPR201899

INTRODUCTION

WEDM is generally used to produce intricate, complex shapes which are impossible to produce by means
of any other conventional and non-conventional machining methods. WEDM is practically versatile applicable in
precision manufacturing industries to manufacture intricate, precise and close tolerance parts with higher accuracy.
When a suitable voltage is supplied across the cathode (thin wire) and anode (workpiece), an electrostatic field of
high strength is established which cause emission of an electron from the tool. In this process, the material is
submerged in the dielectric medium. ‘Dielectric’ is the shield between the working electrode and material.
The emitted electrons get accelerated towards workpiece and collide with the dielectric fields molecules, breaking
them into electrons and ions. The produced electrons accelerate and dislodge. As a result, a spark is produced
between anode and cathode and a very high temperature is developed on the electrode. The high temperature
causes melting and vaporization of the material. A DC or AC servo mechanism maintains the gap between the wire
and the material to prevent the short -circuiting of wire. [1] The block diagram of WEDM is shown in figure 1.

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866 Sandeep Kumar & Subramani. P

Nickel-based superalloys are extensively used in high precision components because of its excellent properties.
However, based on the properties wrought Ni-based Inconel 600 super alloy is a well identified difficult-to-machine super
alloy material. WEDM is revolutionizing machining and can cut all types of intricate and complex shapes up to 45 degrees.
Any material which is electrically conductive can be cut by this process such as tungsten carbide, Inconel and all kinds of
exotic metals. An attempt to use the WEDM process effectively and efficiently, researchers are trying continuously to
improve and optimize the influential process parameters for the machining of highly precise metals. [2]

Figure 1: Schematic of Wire Electro-Discharge Machining (WEDM)

Y. S. Liao et al (1997) reported the influence of WEDM process parameters such as Ton (pulse on time), Toff (Off
time) and feed on the behavior of pulse trains. Experiments were conducted on SKD 11 tool steel. The authors concluded
that in time was a significant factor for pulse trains. [2] N. Tosun et al (2003) presented the impact of machining
parameters of AISI 4140 steel material to measure the crater size of the electrode. The researchers resulted that the crater
size increases with pulse duration, servo voltage, and wire speed whereas it decreases with dielectric pressure. [3] Ulas
Caydas et al (2009) worked on the impact of parameters, i.e. pulse duration, open circuit voltage (SV), wire speed (WS)
and dielectric pressured for the measurement of white layer thickness and SR. They developed the ANFIS model for the
prediction of performance parameters. [4]

Vamsi Krishna Pasam et al (2010) investigated the effect of Ignition pulse current, short pulse duration, wire
speed and wire tension on surface roughness by using Genetic Algorithm (GA). [5] Anish Kumar et al (2012) concluded
that pulse on time (Ton), pulse of time (Toff), peak current (Ip) and spark voltage (SV) had a higher impact on surface
roughness. [6] S. V. Subrahmanyam et al. Concluded that the Gray relational method is the most appropriate for multi-
parametric optimization. A. V. S. Ram Prasad et al (2014) experimentally proved that the peak current (Ip) & pulse on time
(Ton) were dominant parameters to maximize the Material Removal Rate and surface roughness after they studied the effect
of parameters on Ti-6Al-4V alloy. Somvir Singh et al (2016) concluded that the white layer increases with the increase in
pulse on time and for SR and MRR, pulse on time, spark gap voltage and pulse of time are momentous parameters.

Vladimir Simna (2016) reported that the greater height of work material increases the wire breakage probability.
[7] Sameh Habib et al (2017) resulted that the WT (Wire tension), WS (Wire speed), flow rate & SV (Servo voltage)
greatly affect the kerf width and MRR and kerf width decreases with the increase of wire tension and speed. [9] Tompe S.
V. et al reported that the MRR increases with the increase in (Toff) pulse of time. From the literature survey, it is
ascertained that no plausible works were reported for the prediction of SR and cutting speed by hybrid optimization on an
Inconel-600 Ni-based super alloy using a standard brass wire in the WEDM process. Therefore, this experimental analysis
and optimization work are undertaken to optimize the parameters in WEDM by Gray relational method coupled with
Taguchi method.

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Hybrid Optimization of WEDM Parameters to Predict the Influence on 867
Surface Roughness and Cutting Speed for Ni-Based
Inconel 600 Wrought Superalloy
EXPERIMENTAL PLAN

Design-of-experiments (DoE) needs cautions scheduling, the practical layout of the trials, Taguchi has identical
procedures for every DoE application steps and the DoE can dramatically decrease the number of trials. [8, 11] Thus, the
five parameters such as Taper angle (U & V axis taper in degrees), pulse on time (Ton), peak current (Ip), dielectric pressure
and pulse off time (Toff) had selected for the governing parameter, and each parametric quantity had three levels denoted by
level-1, level-2, and level-3except taper angle. Taper angle had two levels, i.e. maximum (2) and minimum (1) angle, as
designated in Table 1.

Table 1: Allocated Values of EDM Constraints and their Levels

Factor Parameter Units Level-1 Level-2 Level-3
X1 Taper degree 2(Max. Angle) 1(Min. Angle) ------------
X2 Peak current (Ip) Amps 110 120 130
X3 Pulse on time (Ton) µs 109 111 113
X4 Pulse off time (Toff) µs 54 58 62
X5 Dielectric pressure Ltr/min. 10 11 12

EXPERIMENTAL SET-UP

As per DoE, the experiments were performed on ELEKTRA Ultima-1F WEDM. Inconel 600 superalloy was used
in the form of the thick rectangular plate. The chemical composition of Inconel 600 superalloy consists of 72% min. Ni &
Co, 14-17 % Cr, 6-10% Fe, 0.50% max. Si, 1% max. Mn, 0.015% max. S, 0.15% max. C and 0.50% max. Cu. It has
excellent mechanical properties, high strength and resistance to corrosion, therefore, this superalloy is mostly demanded in
aerospace, chemical, heat treatment, nuclear and gas turbine industries. The workpiece and the brass wire having DIA. ɸ
0.25 mm electrode was linked up with +ve and –ve polarity in the DC. A power source, respectively. De-ionized water
having a conductivity level of 0.6 µs/cm was used as a dielectric medium. The dielectric fluid was flushed from the top and
bottom nozzles and material were submerged in the dielectric. The WEDM set-up is shown in figure 3.

Figure 2: Experimental set-up of ELEKTRA

Ultima-1F WEDM

The surface roughness of the machined material was measured with Mitutoyo surf test surface roughness testers.
Each trial was evaluated thrice and the mean values were obtained.

The mathematical relation used to evaluate the Surface roughness (SR) is given below:

L
1
Zx 〈 dx〉 (µm) (1)
L ∫0
SurfaceRoughness ( Ra ) =

Where ; Ra is the surface roughness value measured in µm, L = evaluation length ;Z(x) = profiles height function.

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868 Sandeep Kumar & Subramani. P

The ANOVA mathematical relation (Higher is the better) utilized to calculate the S/N ratio of Cutting speed is given
below:

 n 
(2)
η
1
= −10 log  ∑ yi 
HB  n i =1 
 

The ANOVA mathematical relation (Lower is the better) used to calculate the S/N ratio of SR is given below:

 n 
(3)
η
1 1
= −10 log  ∑ 2 
LB  n i =1 yi 
 

The S/N ratio nij for the ith performance characteristics in the jth experiment is evaluated by following relation :

η ij
= −10 log[ Lij ] (4)

Where ; y=observed data and n= no. of trials

DOE (Design of Experiment) AND MULTI-PARAMETRIC OPTIMIZATION

The aim of this experimental analysis is to increase the cutting rate and to minimize the value of surface
roughness. In the present experimentation work, L18 (2^1 3^4) mixed Orthogonal Array (OA) was chosen. This OA has 18
parametric combinations, therefore, the total number of 18 experiments were conducted to measure the interactions
between the various factors. The parameter combinations using the L18 (2^1 3^4) mixed OA are shown in Table 2.

Table 2: DOE Matrix of L18 Mixed Orthogonal Array (OA)

Sl. Taper Ip Ton Toff Dielectric pressure
No. (X1) (X2) (X3) (X4) (X5)
1. 2 110 109 54 10
2. 2 110 113 58 11
3. 2 110 113 62 12
4. 2 120 109 54 11
5. 2 120 111 58 12
6. 2 120 113 62 10
7. 2 130 109 58 10
8. 2 130 111 62 11
9. 2 130 113 54 12
10. 1 110 109 62 12
11. 1 110 111 54 10
12. 1 110 113 58 11
13. 1 120 109 58 12
14. 1 120 111 62 10
15. 1 120 113 54 11
16. 1 130 109 62 11
17. 1 130 111 54 12
18. 1 130 113 58 10

For accurate measurements minimum, three values were taken for each specimen and the mean value was
selected. The mean values of the Surface roughness and cutting rate are shown in Table 3.

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Hybrid Optimization of WEDM Parameters to Predict the Influence on 869
Surface Roughness and Cutting Speed for Ni-Based
Inconel 600 Wrought Superalloy
Table 3: Measured Values for Output Responses, as Per DOE
Surface Roughness Cutting Speed S/N Ratio S/N Ratio
SI. No.
(Ra) (mm/min.) (Surface roughness) (Cutting Rate)
1. 1.56 0.876 -3.86249 -1.14992
2. 1.74 0.939 -4.81098 -0.54669
3. 2.05 0.987 -6.23508 -0.11366
4. 1.74 0.944 -4.81098 -0.50056
5. 1.95 0.989 -5.80069 -0.09607
6. 2.09 1.072 -6.40293 0.603896
7. 2.69 2.304 -8.59505 7.249649
8. 2.59 1.915 -8.266 5.643376
9. 2.75 3.070 -8.78665 9.742768
10. 1.29 0.590 -2.21179 -4.58296
11. 1.77 1.054 -4.95947 0.456812
12. 2.03 1.070 -6.14992 0.587676
13. 1.54 0.720 -3.75041 -2.85335
14. 1.74 0.780 -4.81098 -2.15811
15. 2.14 1.479 -6.60828 3.399363
16. 2.40 1.860 -7.60422 5.390259
17. 2.64 3.240 -8.43208 10.2109
18. 2.52 2.010 -8.02801 6.063921

MULTI-PARAMETRIC HYBRID OPTIMIZATION USING THE

TAGUCHI AND GREY RELATIONAL METHOD

The steps used for multi-parametric optimization using the Gray relational analysis is discussed below;

a) Normalization of the All Experimental Results of SR and Cutting Rate: Linear normalization of experimental
values is performed in the range of 0 and 1. The normalized values for output responses were calculated by using
the standard formula:

( ) (
( )= (5)
( !" ) ( #" !" )

Where,

yij = ith experiment results in jth experiment.

b) Calculation of the Gray Relational Coefficients:

Grey relational coefficients are evaluated to express the relation between the ideal and factual experimental
consequences. The standard formula used for the computation of Grey relational coefficients is given below:

#" # % °" " %& ' " % °" " %

δ$ = , 0<+<1 (6)
% °" " %&' " " % °" %

Where,

xᵒi = ideal normalized result

Table 4: Calculated Values for Normalization and Deviation Sequence

S/N Ratio Normalization Deviation Sequence
SI.
Surface Cutting Surface Cutting Surface Cutting
No.
Roughness speed Roughness speed Roughness speed
1. -3.86249 -1.14992 0.748937948 0.130389 0.251062 0.869611

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870 Sandeep Kumar & Subramani. P

Table 4: Contd.,
2. -4.81098 -0.54669 0.604677379 0.176563 0.395323 0.823437
3. -6.23508 -0.11366 0.388080778 0.209709 0.611919 0.790291
4. -4.81098 -0.50056 0.604677379 0.180094 0.395323 0.819906
5. -5.80069 -0.09607 0.454148347 0.211055 0.545852 0.788945
6. -6.40293 0.60390 0.362551944 0.264634 0.637448 0.735366
7. -8.59505 7.24965 0.029142565 0.773332 0.970857 0.226668
8. -8.26600 5.64338 0.079189309 0.650380 0.920811 0.349620
9. -8.78665 9.74277 0 0.964167 1.000000 0.035833
10. -2.21179 -4.58296 1 -0.132393 0.000000 1.132393
11. -4.95947 0.45681 0.582094332 0.253376 0.417906 0.746624
12. -6.14992 0.58768 0.401032608 0.263393 0.598967 0.736607
13. -3.75041 -2.85335 0.765984327 0.000000 0.234016 1.000000
14. -4.81098 -2.15811 0.604677379 0.053217 0.395323 0.946783
15. -6.60828 3.39936 0.331319377 0.478613 0.668681 0.521387
16. -7.60422 5.39026 0.179840955 0.631005 0.820159 0.368995
17. -8.43208 10.21090 0.053928959 1.000000 0.946071 0.000000
18. -8.02801 6.06392 0.115385438 0.682570 0.884615 0.317430

c) Calculation For the Gray Relational Grade

Gray relational grades are evaluated by the average of Gry relational coefficient using the formula given below:

-
α$ = . δ$ (7)
/-

Where,

αj = Gry relational grade

m = No. of execution grade characteristics

Table 5: Calculated Values for Gray Relational Coefficients and Grades

Gray Relational Coefficients Gray Relational
SI. No.
Surface Roughness Cutting Speed Grade
1. 0.400340 0.793161 0.596751
2. 0.452621 0.739030 0.595825
3. 0.563012 0.704514 0.633763
4. 0.452621 0.735193 0.593907
5. 0.524028 0.703180 0.613604
6. 0.579675 0.653908 0.616791
7. 0.944925 0.392671 0.668798
8. 0.863276 0.434639 0.648957
9. 1.000000 0.341491 0.670746
10. 0.333333 1.360147 0.84674
11. 0.462067 0.663680 0.562873
12. 0.554919 0.654971 0.604945
13. 0.394950 1.000000 0.697475
14. 0.452621 0.903804 0.678213
15. 0.601454 0.510927 0.556191
16. 0.735466 0.442085 0.588775
17. 0.902643 0.333333 0.617988
18. 0.812499 0.422808 0.617653

d) Calculation of the Optimum Levels: Optimum Levels are Calculated to Find the Significant Parameter.

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Hybrid Optimization of WEDM Parameters to Predict the Influence on 871
Surface Roughness and Cutting Speed for Ni-Based
Inconel 600 Wrought Superalloy
Table 6: Gray Relational Grade Response Table
Parameters Level-1 Level-2 Level-3
X1 0.626571294 0.641205873 -----------
X2 0.640149501 0.626030003 0.635486248
X3 0.665407575 0.61957673 0.616681446
X4 0.599742484 0.633050017 0.668873251
X5 0.623513172 0.598100031 0.680052549
Average Gray relational Grade= 0.63389

e) Selection of the optimum levels of process constraints by taking the highest values of levels for each parameter
from the optimum level table. The Response table is clearly indicating the level values for process parameters.
The highest value of process parameters for each parameter showed the best- optimized value.

f) Confirmation of experiment and verification of the optimized process parameters.

CONFIRMATION OF EXPERIMENT

After obtaining the optimized values of process parameters the last step is to confirm the experimentation.

The mathematical relation used to calculate the estimated Gray relational grade is given below:
5
α0 = 1 + 3 /-(α − α ) (8)

Where,

αm = Total mean of the Gray relational grade at the optimum level

q = No. of process parameters.

Table 7: Confirmation of Experiment

Predicted Value Experimentation
Level X12X22X31X42X53 X12X21X31X43X53
Surface Roughness (µm) 1.54 1.29
Cutting rate (mm/min.) 0.720 0.590
Grade 0.69747 0.84674
Improvement in Gray Relational Grade: 0.14927

RESULTS AND CONCLUSIONS

• The optimized parameters for the response of SR (Ra value) and cutting rate in WDM are 110 Amps of Peak
current (Ip), 109 µs Pulse on time (Ton), 62 µs Pulse of time (Toff), 12 liter/min. Dielectric flow and minimum taper
angle.

• The WEDM process parameters for super-alloy namely Inconel-600 has been optimized by Gray relational
method coupled with Taguchi method.

• The optimal solution had calculated for surface roughness (SR) and cutting speed.

• An attempt had also been made to attain minimum and maximum evaluation of surface roughness (SR) and
cutting speed respectively. The attained optimum outcomes had also been examined through a real experiment
and established to be satisfactory.

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872 Sandeep Kumar & Subramani. P

• For surface roughness, the Ip and pulse on time (Ton) are the most significant parameter and the dielectric pressure
is the least significant parameter.

• For cutting speed, peak current (Ip) and Toff are the most influencing parameter and taper angle is the least
influencing parameter.

• The experimental results showed the considerable advancement in the process. The experimental results will
facilitate the WEDM industries to improve the productivity, performances and cutting rate with the higher surface
finish.

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